Low-phosporous nickel-coated carbon microcoils: Controlling microstructure through an electroless plating process

Carbon microcoils (CMCs) have been coated with a nickel-phosphorus (Ni-P) film using an electroless plating process, with sodium hypophosphite as a reducing agent in an alkaline bath. CMC composites have potential applications as microwave absorption materials. The morphology, elemental composition and phases in the coating layer of the CMCs and Ni-coated CMCs were investigated by scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD), respectively. The effects of process parameters such as pH, temperature and coating time of the plating bath on the phosphorus content and deposition rate of the electroless Ni-P coating were studied. The results revealed that a continuous, uniform and low-phosphorous nickel coating was deposited on the surface of the CMCs for 20 min at pH 9.0, plating bath temperature 70 °C. The as-deposited coatings with approximately 4.5 wt.% phosphorus were found to consist of a mix of nano- and microcrystalline phases. The mean particle size of Ni-P nanoparticles on the outer surface of the CMCs was around 11.9 nm. The deposition rate was found to moderately increase with increasing pH, whereas, the phosphorous content of the deposit exhibited a significant decrease. Moreover, the material of the coating underwent a phase transition between an amorphous and a crystalline structure. The thickness of the deposit and the deposition rate may be controlled through careful variation of the coating time and plating bath temperature.     

Evaluation of copper ion of antibacterial effect on Pseudomonas aeruginosa, Salmonella typhimurium and Helicobacter pylori and optical, mechanical properties

Antibacterial effect on Pseudomonas aeruginosa, Salmonella typhimurium and Helicobacter pylori of copper ion was researched. Also, additional effects of copper ion coating on optical and mechanical properties were researched as well. Copper ion was coated on glass substrate as a thin film to prevent bacteria from growing. Cupric nitrate was used as precursors for copper ion. The copper ion contained sol was deposited by spin coating process on glass substrate. Then, the deposited substrates were heat treated at the temperature range between 200 °C and 250 °C. The thickness of deposited copper layer on the surface was 63 nm. The antibacterial effect of copper ion coated glass on P. aeruginosa, S. typhimurium and H. pylori demonstrated excellent effect compared with parent glass. Copper ion contained layer on glass showed a similar value of transmittance compared with value of parent glass. The 3-point bending strength and Vickers hardness were 209.2 MPa, 540.9 kg/mm² which were about 1.5% and 1.3% higher than the value of parent glass. From these findings, it is clear that copper ion coating on glass substrate showed outstanding effect not only in antibacterial activity but also in optical and mechanical properties as well.     

Effects of copper concentration on electro-optical and structural properties of chemically deposited nanosized (Zn-Cd)S:Cu films

Nanocrystalline (Zn-Cd)S films have been co-deposited on glass slide substrates by chemical bath deposition (CBD) technique at 70 °C for 75 min. Electroluminescent (EL), photoluminescent (PL) and structural characteristics of these films doped with Cu have been investigated. Cu doping has significant effects on the growth, structural and optical properties of the deposited (Zn-Cd)S films. EL studies show the essentiality of copper for EL emission. The effect of Cu concentration is examined on XRD, SEM, UV-vis spectroscopy, etc. The morphology of these films investigated with SEM and XRD is used to determine crystalline nature of the films. The optical absorption coefficient of the films has been found to increase with increase in Cu concentration. Voltage and frequency dependence shows the effectiveness of acceleration-collision mechanism. The trap-depth values are calculated from temperature dependence of EL brightness.     

Characteristics and heat treatment of cold-sprayed Al-Sn binary alloy coatings

In this study, Al-Sn binary alloy coatings were prepared with Al-5 wt.% Sn (Al-5Sn) and Al-10 wt.% Sn (Al-10Sn) gas atomized powders by low pressure and high pressure cold spray process. The microstructure and microhardness of the coatings were characterized. To understand the coarsening of tin in the coating, the as-sprayed coatings were annealed at 150, 200, 250 and 300 °C for 1 h, respectively. The effect of annealing on microstructure and the bond strength of the coatings were investigated. The results show that Al-5Sn coating can be deposited by high pressure cold spray with nitrogen while Al-10Sn can only be deposited by low pressure cold spray with helium gas. Both Al-5Sn and Al-10Sn coatings present dense structures. The fraction of Sn in as-sprayed coatings is consistent with that in feed stock powders. The coarsening and/or migration of Sn phase in the coatings were observed when the annealing temperature exceeds 200 °C. Furthermore, the microhardness of the coatings decreased significantly at the annealing temperature of 250 °C. EDXA analysis shows that the heat treatment has no significant effect on fraction of Sn phase in Al-5Sn coatings. Bonding strength of as-sprayed Al-10Sn coating is slightly higher than that of Al-5Sn coating. Annealing at 200 °C can increase the bonding strength of Al-5Sn coatings.     

Fabrication of silver stabilization layer of coated conductor using organic silver complexes

Silver stabilizing layer of coated conductor has been prepared by dip coating method using organic silver complexes containing 10 wt.% silver as a starting material. Coated silver complex layer was dried in situ with hot air and converted to crystalline silver by post heat treatment in flowing oxygen atmosphere. A dense continuous silver layer with good surface coverage and proper thickness of 230 nm is obtained by multiple dip coatings and heat treatments. The film heat treated at 500 °C showed good mechanical adhesion and crystallographic property. The interface resistivity between superconducting YBCO layer and silver layer prepared by dip coating was measured as 0.67 × 10⁻¹³ Ω m².     

Ultrasonic characterization of thermally grown oxide in thermal barrier coating by reflection coefficient amplitude spectrum

The thermally grown oxide (TGO) growth at the interface of ceramic coating/bond coating in thermal barrier coatings (TBCs) was evaluated by ultrasonic reflection coefficient amplitude spectrum (URCAS). A theoretical analysis was performed about the influence of acoustic impedance match relationship between the ceramic coating and its adjacent media on URCAS. The immersion ultrasonic narrow pulse echo method was carried out on the TBC specimen before and after oxidation under 1050 °C × 1 h for 15 cycles. The resonant peaks of URCAS obtained before and after oxidation showed that TGO which generated between the ceramic coating and bond coating due to the oxidation, changed the acoustic impedance match between the ceramic coating and its adjacent media. This method is able to nondestructively characterize the generation of TGO in TBCs, and is important to practical engineering application.     

Chemical reactivity of PVD-coated WC-Co tools with steel

The chemical reactivity of CrN, ZrN, TiC_xN_1−x and naCo^® PVD coatings on a WC-Co cemented carbide substrate with steel has been evaluated by means of the static interaction couples technique. Diffusion experiments with coated and uncoated tools were carried out at 900, 1100 and 1300 °C in order to establish the maximum temperature at which the substrate-coating-workpiece combinations are chemically stable. Computational equilibrium thermodynamics was used to identify the interaction products formed at elevated temperature and the chemical solubility of the different coating materials into iron. A metallic (Fe, Co) fcc solid solution was identified at the steel side of the interface from 1100 °C on for all the coated tools and from 900 °C for the uncoated carbide. In addition to this interaction product, the ?-carbide was identified at 1300 °C on the WC-Co side of the interface. Both of the experimental findings and thermodynamic equilibrium solubility calculations demonstrated that the PVD-coated WC-Co tools exhibit a lower chemical reactivity with respect to the uncoated tools.     

Investigation of oxidation inhibition properties of vaporized self-assembled multilayers on copper nanopowders

Stability against oxidation was investigated for vaporized self-assembled multilayers on nano-sized Cu powders. 100 nm-sized copper powders were coated with 1-octanethiol to make a passivation layer against oxidation.As a result, the surface resistivity of the coated and uncoated nano-sized copper powders differed by two orders of magnitude. XPS analysis was used to monitor changes in the amount of sulfur and oxygen on the surface of octanethiol-coated Cu nano powders over a period of time. While sulfur was detected for up to 75 days, the amount of oxygen increased dramatically after 35 days, indicating sign of partial oxidation. Furthermore, HR-TEM images showed that the octanethiol film was consistently 10 nm thick, for up to 35 days. After 35 days exposure to the air, the octanethiol film was partially damaged and its diffraction pattern detected the presence of Cu₂O. Based on these findings, vaporized octanethiol coating protected the copper nano powders from oxidation for up to 35 days. Therefore this oxidation inhibition property of VSAMs coating method on Cu powders achieves a great milestone toward inkjet printing technology.     

Deposition and characterization of TiAlSiN nanocomposite coatings prepared by reactive pulsed direct current unbalanced magnetron sputtering

This work reports the performance of high speed steel drill bits coated with TiAlSiN nanocomposite coating at different Si contents (5.5-8.1 at.%) prepared using a four-cathode reactive pulsed direct current unbalanced magnetron sputtering system. The surface morphology of the as-deposited coatings was characterized using field emission scanning electron microscopy. The crystallographic structure, chemical composition and bonding structure were evaluated using X-ray diffraction, energy-dispersive X-ray analysis, X-ray photoelectron spectroscopy, respectively. The corrosion behavior, mechanical properties and thermal stability of TiAlSiN nanocomposite coatings were also studied using potentiodynamic polarization, nanoindentation and Raman spectroscopy, respectively. The TiAlSiN coating thickness was approximately 2.5-2.9 μm. These coatings exhibited a maximum hardness of 38 GPa at a silicon content of approximately 6.9 at.% and were stable in air up to 850 °C. For the performance evaluation, the TiAlSiN coated drills were tested under accelerated machining conditions by drilling a 12 mm thick 304 stainless steel plate. Under dry conditions the uncoated drill bits failed after drilling 50 holes, whereas, TiAlSiN coated drill bits (Si = 5.5 at.%) drilled 714 holes before failure. Results indicated that for TiAlSiN coated drill bits the tool life increased by a factor of more than 14.     

Diffusion research between Ni3Al coating and titanium alloy produced by plasma spraying process

A Ni₃Al coating was prepared by plasma spraying technique on the surface of titanium alloy. Ni-Al mixed powders, coatings and reaction products were investigated by scanning electron microscope, EDS, DSC and XRD. A tight bonding between the coating and the substrate was formed. The X-ray diffraction analysis of the patterns showed that the coating not only had Ni₃Al phase, but also had NiO and Al₂O₃ phase microcontent. Comparing Ni coated Al to Ni₃Al at 900 °C, the diffusion was stronger and the diffusion layer was thicker. A minute pore structure was formed at 1200 °C in the front edge of solid-state reaction layer. So Ni₃Al restrained the solid-state reaction of the coating with the substrate, and as a whole weakened the entry of oxygen atoms into the substrate and quenched the out-diffusion of titanium.     

Effect of annealing on properties of electrochemically deposited CdTe thin films

Thin films of CdTe have been deposited onto stainless steel and fluorine-doped tin oxide (FTO)-coated glass substrates from aqueous acidic bath using electrodeposition technique. The different preparative parameters, such as deposition time, bath temperature and pH of the bath have been optimized by photoelectrochemical (PEC) technique to get good quality photosensitive material. The deposited films are annealed at different temperature in presence of air. Annealing temperature is also optimized by PEC technique. The film annealed at 200 °C showed maximum photosensitivity. Different techniques have been used to characterize as deposited and also as annealed (at 200 °C) CdTe thin film. The X-ray diffraction (XRD) analysis showed the polycrystalline nature, and a significant increase in the XRD peak intensities is observed for the CdTe films after annealing. Optical absorption shows the presence of direct transition with band gap energy 1.64 eV and after annealing it decreases to 1.50 eV. Energy dispersive analysis by X-ray (EDAX) study for the as-deposited and annealed films showed nearly stoichiometric compound formation. Scanning electron microscopy (SEM) reveals that spherically shaped grains are more uniformly distributed over the surface of the substrate for the CdTe film.     

The study on porosity and thermophysical properties of nanostructured La2Zr2O7 coatings

Lanthanum-zirconium nano-powders were synthesized by molten salts method. Nanostructured lanthanum-zirconium coatings were deposited by air plasma spraying. Scanning electron microscopy and X-ray diffraction were carried out to analyze the as-sprayed coatings and powders. The pore size distribution and buck density of coatings were identified by mercury intrusion porosimetry. The thermophysical properties of the nanostructured coatings were also examined through laser flash technique and differential scanning calorimetry. The results demonstrate that the as-sprayed nanostructured coatings consist of the pyrochlore-type phase. The as-sprayed nanostructured lanthanum-zirconium coatings have a very low porosity. The thermal conductivity of the as-sprayed nanostructured lanthanum-zirconium coating is lower than that of the conventional coating between 200 °C and 950 °C, but when the temperature between 950 °C and 1300 °C, the result is reverse.     

Room temperature synthesis of water repellent silica coatings by the dip coat technique

The present paper describes the room temperature synthesis of dip coated water repellent silica coatings onto stainless steel substrates using 1,1,1,3,3,3-hexamethyldisilazane as a surface modifying agent. The hydrophobic property of the silica coating was enhanced by increasing its surface roughness, which was achieved by a proper control over the MeOH/TMOS molar ratio (S) during the synthesis. The contact angle of a water droplet (10 μl) increased from 72° to 145° with an increase in the S value from 9.1 to 36.4. The silica coating showed a minimum sliding angle of 15° for a water droplet of 10 μl. The water repellent silica coatings are thermally stable up to a temperature of 340 °C. The results have been discussed by taking into consideration the contact angle measurements, surface morphology and sol-gel parameters.     

High temperature oxidation behavior of interconnect coated with LSCF and LSM for solid oxide fuel cell by screen printing

The current study examined the effect of La_0.6Sr_0.4Co_0.2Fe_0.8O₃ (LSCF) and La_0.7Sr_0.3MnO₃ (LSM) coatings on the electrical properties and oxidation resistance of Crofer22 APU at 800 °C hot air. LSCF and LSM were coated on Crofer22 APU by screen printing and sintered over temperatures ranging from 1000 to 1100 °C in N₂. The coated alloy was first checked for compositions, morphology and interface conditions and then treated in a simulated oxidizing environment at 800 °C for 200 h. After measuring the long-term electrical resistance, the area specific resistance (ASR) at 800 °C for the alloy coated with LSCF was less than its counterpart coated with LSM. This work used LSCF coating as a metallic interconnect to reduce working temperature for the solid oxide fuel cell.     

Laser synthesis of palladium-alumina composite membranes for production of high purity hydrogen from gasification

This paper describes a special method of laser-based deposition to synthesize palladium-ceramic composite membranes. Thin film Pd was deposited on a ceramic substrate by Nd-YAG laser irradiation of coating precursor PdCl₂ on γ-alumina substrate. The parameters of the laser processing technique were optimized to synthesize metal-ceramic composite membranes. The physical and chemical characteristics of Pd coated γ-alumina membranes were studied and compared with various other alumina membranes referenced in the literature. Hydrogen permeation experiments were performed in a CO + CO₂ + CH₄ + H₂ environment under typical catalytic steam gasifier exit conditions. The Pd-ceramic composite showed good mechanical and thermal stability and resulted in a hydrogen permeability flux of about 0.061 mol/m² s. The activation energy of the Pd membrane was found to be 5.39 kJ/mol in a temperature range of 900-1300 °F.     

Soot capture and combustion for perovskite La-Mn-O based catalysts coated on honeycomb ceramic in practical diesel exhaust

Nanosized perovskite oxides of LaMnO₃, La_0.8K_0.2MnO₃ and La_0.8K_0.2Co_0.5Mn_0.5O₃ with grain sizes about 16-28 nm were prepared by the citrate-gel process and their coatings with thickness about 30 μm and a coherent interface between the coating and the honeycomb ceramic were obtained by the sol-gel assisted dip-coating technique. The powders and coatings were characterized by X-ray diffraction, Fourier transform infrared spectroscopy and scanning electron microscopy. The specific surface area was measured by the Brunauere-Emmette-Teller method. The catalytic performance was evaluated by thermo-gravimetric analysis under model conditions and by the smoke opacity measurement for the practical exhaust gas emissions at 200-400 °C, respectively. The results show that all three perovskite oxide catalysts have a capture effect of soot and a catalytic activity for soot combustion. The capture effect is mainly related to the porous structural characteristic of the catalyst and the catalytic performance for soot combustion is largely affected by the chemical composition, grain size, specific surface area and pore structure, which are related to the ions substitution and calcination temperature. Among these three catalysts, La_0.8K_0.2MnO₃ shows the best comprehensive catalytic performance and the La_0.8K_0.2MnO₃ coated honeycomb ceramic will be a promising device for diesel exhaust gas emissions.     

Bismuth zinc niobate (Bi1.5ZnNb1.5O7) ceramics derived from metallo-organic decomposition precursor solution

The preparation, microstructure development and dielectric properties of Bi_1.5ZnNb_1.5O₇ pyrochlore ceramics by metallo-organic decomposition (MOD) route are reported. Homogeneous precalcined ceramic powders of 13-36 nm crystallite size were obtained at temperatures ranging from 500 to 700 °C. The thermal decomposition/oxidation of the gelled precursor solution was chemically analyzed, TG/DTA, XRD, and SEM, led to the formation of a pure cubic pyrochlore phase with a stoichiometry close to Bi_1.5ZnNb_1.5O₇ which begins to form at 500 °C. The metallo-organic precursor synthesis method, where Bi, Zn and Nb ions are chelated to form metal complexes, allows the control of Bi/Zn/Nb stoichiometric ratio on a molecular scale leading to the rapid formation of bismuth zinc niobate (Bi_1.5ZnNb_1.5O₇) ceramic fine powders with pure pyrochlore structure. The powders were pressed into pellets and can be sintered at temperatures as low as 800-1000 °C. Fine crystalline ceramics with the grain size in the range of 200-500 nm have been obtained at the sintering temperature of 800 °C. The dielectric properties in high frequency to microwave range were measured and discussed.     

Si layer transfer to InP substrate using low-temperature wafer bonding

Using a low-temperature wafer bonding process, InP substrates are bonded to silicon-on-insulator (SOI) substrates at 220 °C. A combination of oxygen plasma and chemical treatment results in a direct contact bonding at room temperature. After the bonding process at 220 °C for 45 min, removal of the Si handle substrate by sacrificial etching of the buried oxide layer in SOI, results in a thin membrane of Si robustly bonded to InP. The thin Si membrane bonded to InP shows uniformly bonded interface under high-resolution electron microscopy. Micro-Raman analysis has also been carried out to study the bonded interface. I-V characteristics of the bonded structures suggest that such bonding and layer transfer processes are suitable for device integration.     

Characterization and corrosion behavior of hydroxyapatite/zirconia composite coating on NiTi fabricated by electrochemical deposition

NiTi alloy is used as biomaterial due to its unique properties, but the high content of Ni (about 50 at.%) in biomedical NiTi is concerned. Hydroxyapatite and hydroxyapatite/zirconia composite coatings were directly electrodeposited on NiTi alloy surface. The coated samples were characterized using X-ray diffraction, scanning electron microscopy, infrared spectroscopy, bonding strength test, polarization and EIS. Results showed that when ZrO₂ was added into the electrolyte, morphology of HAP was changed from thin flake-flower-like crystals to needle-flower-like crystals, and coating was denser. Besides, HAP crystal grains in the coating were preferentially arranged in the [0 0 1] direction. Addition of ZrO₂ could improve the bonding strength between the coating and the substrate. Corrosion resistance of NiTi in the simulated body fluid at 37 °C was significantly improved by almost 60 times by electrodeposition of the hydroxyapatite/zirconia composite coating.     

Influence of heat treatment on tribological properties of electroless Ni-P and Ni-P-Al2O3 coatings on Al-Si casting alloy

Evolution of tribological properties of electroless Ni-P and Ni-P-Al₂O₃ coating on an Al-10Si-0.3Mg casting alloy during heat treatment is investigated in this work. The pre-treated substrate was plated using a bath containing nickel hypophosphite, nickel lactate and lactic acid. For preparation of fiber-reinforced coating Al₂O₃ Saffil fibers pre-treated in demineralised water were used. The coated samples were heat treated at 400-550 °C/1-8 h. Tribological properties were studied using the pin-on-disc method. It is found that the best coating performance is obtained using optimal heat treatment regime (400 °C/1 h). Annealing at higher temperatures (450 °C and above) leads to the formation of intermetallic compounds that reduce the coating wear resistance. The reason is that the intermetallic phases adversely affect the coating adherence to the substrate. The analysis of wear tracks proves that abrasion is major wear mechanism, however due to the formed intermetallic sub-layers, partial coating delamination may occur during the pin-on-disc test on the samples annealed at 450 °C and above. It was found that fiber reinforcement reduces this scaling and increases wear resistance of coatings as compared to the non-reinforced Ni-P coatings.